Catalyst for ammonia synthesis and a process producing the catalyst

ABSTRACT

A NOVEL CATALYST FOR AMMONIA SYNTHESIS AND A PROCESS FOR PRODUCING THE CATALYST ARE DESCRIBED. THE CATALYST COMPRISES (A) GRAPHITE, (B) A TRANSITION METAL COMPOUND AND (C) AN ALKALI METAL. THE CATALYST OF THIS INVENTION IS CAPABLE OF SYNTHESIZING AMMONIA FROM HYDROGEN AND NITROGEN OR AIR AT A RELATIVELY LOW TEMPERATURE EVEN AT ROOM TEMPERATURE UNDER NORMAL OR A REDUCED PRESSURE.

United States Patent Ofice Patented Aug. 20, 1974 US. Cl. 252-441 Claims ABSTRACT OF THE DISCLOSURE A novel catalyst for ammonia synthesis and a process for producing the catalyst are described. The catalyst comprises (a) graphite, (b) a transition metal compound and (c) an alkali metal. The catalyst of this invention s capable of synthesizing ammonia from hydrogen and nitrogen or air at a relatively low temperature even at room temperature under normal or a reduced pressure.

BACKGROUND OF THE INVENTION The present invention relates to a catalyst for ammonia synthesis. More particularly, this invention relates to a catalyst for ammonia synthesis comprising (a) graphite, (b) at least one of transition metal compound and (c) an alkali metal.

Conventional commercial processes for ammonia synthesis include Haber-Bosch Process, Claude Process and Mont-Cenis Process. As the main ingredient of the catalyst, the first two are produced from molten iron oxide, while the last one is produced from an iron-cyano complex salt. All three of these catalysts are produced by subjecting a mixture of an iron compound and promoter to a reduction treatment.

However, all these processes for ammonia synthesis are carried out at a high temperature (about 300 to 500 C.) and under a high pressure (about 500 to 1,000 atm.). Further, these processes are accompanied by a defect in that high-purity hydrogen and nitrogen are required, because the activity of the catalyst is diminished with the presence of oxygen and carbon monoxide in the synthesis gas.

DETAILED DESCRIPTION OF THE INVENTION The catalyst according to the present invention is novel, being entirely different from any one of the conventional catalysts in respect of composition. Furthermore, the catalyst according to this invention is capable of synthesizing ammonia at a relatively low temperature even at room temperature and under normal or reduced pressure. However, the reaction temperature is preferably about 200 to 350 C. In addition, the activity of the catalyst is not adversely affected *with the presence of oxygen and carbon monoxide. Further, the catalyst according to this invention does not require being subjected to a reduction treatment.

The catalyst according to the present invention is complex compound, which comprises:

(a) at least one of alkali metals belonging to Group 1A of the Periodic Table.

(b) at least one of the halides, oxides and sulfides of a transition metal selected from the group of metals consisting of Group 4B, Group 5B, Group 6B, Group 7B and Group 8 of the Periodic Table and (c) graphite.

This complex compound comprises alkali metals as electron donors, graphite as an electron acceptor and at least one of said transition metal compounds. Thus, this complex compound is generally called as an electron donor-acceptor complex. In the catalyst, the weight ratio of the transition metal compound to graphite is generally about 0.001-1:l, preferably 0.01-0.5zl, and the weight ratio of alkali metal to graphite-transition metal interlayer complex compounds is generally about 01-1011 and preferably 0.5-1.0:1. Graphite employed for preparation of the catalyst can be produced by pyrolysis of a carboncontaining material, such as coal pitch coke and petroleum pitch coke, a gaseous hydrocarbon such as methane and ethane and carbon. The preferred graphite is produced by pyrolysis of active carbon.

The catalyst according to this invention can be produced by means of (1) subjecting a mixture of graphite and a transition metal compound to a heat treatment at a temperature of from about 250 to 500 C. for about 5 to 20 hours, (2) adding an alkali metal to the thus heat-treated mixture and thereafter (3) heating the product under a reduced pressure for example less than 10- cm. Hg, preferably less than 10- cm. Hg or in an inert gas atmosphere such as argon and nitrogen, at a temperature above the melting point of the alkali metal.

The catalyst according to this invention exhibits are-- markable adsorption of hydrogen and nitrogen. When a mixture of hydrogen and nitrogen is brought into contact with this catalyst, ammonia is formed. Likewise, with the use of the catalyst according to this invention, it is also possible to synthesize ammonia from hydrogen and air.

On the other hand, if any one or two of (a) an alkali metal, (b) graphite and (c) said specified transition metal compound are employed individually or in combination, respectively, the formation of ammonia is extremely low. In contrast, when a three-component catalyst of this invention is used, it becomes possible to increase the ammonia formation by about hundred times the said one or two-component catalyst.

The decomposition of ammonia proceeds reversibly on the catalyst of this invention, as in the case of common catalysts for the ammonia synthesis. Thus, hydrogen and nitrogen are converted on the catalyst into ammonia with a high yield at a low temperature and under a high pressure, under such conditions an equilibrium ammonia concentration is high enough.

DESCRIPTION OF PREFERRED EMBODIMENTS The present invention will be further explained in detail by means of Examples. It should be understood that this invention is, however, in no way limited by the Examples, which are given for the purpose of only illustration of this invention. All parts given in Examples are parts by weight, unless otherwise indicated.

Example 1 Two parts of graphite and 0.2 part of ferric chloride were charged into a U-shaped glass reactor and heated at 300 C. for 20 hours under a reduced pressure to form a graphite-ferric chloride interlayer complex compound. Thereafter, 2 parts of metallic potassium was added to said complex compound and the mixture was molten at 300 C. for 20 hours under a pressure of 10 cm. Hg to form a three-component catalyst consisting of graphite, ferric chloride and potassium. The surface area of the thus formed catalyst was measured according to the BET Method and found to be about 20 m? per gram.

Ammonia synthesis gas of nitrogen and hydrogen was circulated at a rate of 15 cc. per minute and under a pressure listed in Table 1 into a 300 cc. capacity of reactor packed with 4.2 g. of the catalyst produced as above. Thereafter, the ammonia gas collected into a cooler (liquid nitrogen trap) was subjected to qualitative and quantitative analysis by means of gas chromatography and infrared spectroscopy. When air was used as a source of nitrogen, the catalytic activity was not lowered even with the presence of carbon monoxide in an amount corresponding to the partial pressure of 10 to 40 cm. Hg. The reaction conditions and the results are as shown in Table 1 below pany) and 0.2 part of nickel chloride. The charged mass was heated at 500 C. for 20 hours under a reduced pressure to form a graphite-nickel chloride interlayer complex compound. Thereafter, 2 parts of metallic potassium was added to the charged mass and the mixture TABLE 1 5 was sub ected to melting treatment at 300 C. for 20 BMW hours under a pressure of 10- cm. Hg to form a three- Partial Pressure tion iormeg NIL/ N, component catalyst consisting of potassium, nickel chlo Catalyst 3: ffl 33 g-g 23$; ride and graphite. The surface area of the thus formed Ki 1 10 30 300 42 1 10 catalyst was about 20 m? per gram as measured according err C chloride- 12 42 170 4 0.10 to the T Methodgraphite 13 40 110 1.3 0. 03 Into Said reactor packed with 4.2 grams of the threeg Z5 8:? 9 83 component catalyst was introduced and recirculated a synthesis gas of hydrogen and nitrogen at a rate of 15 Example 2 15 cc. per minute. Ammonia collected into a cooler was sub ected to the qualitative and quantitative analysis Catalysts were f' accordmg to h procedures through gas chromatography and infrared spectroscopy. as Example 1 uslng 2 Parts graphlte a a The results are shown in Table 5 below. When air was determined amount of ferrlc chlorlde and various alkali used as a Source of nitrogen, it was Observed that the a BY l grfims of these catalysts the 90 catalytic activity was not decreased, nor with the presg syltltilestls was g i g F surface area i f ence of carbon monoxide in an amount corresponding to a o e ca a ys s was a on m. per gram, respec 1ve y. artial ressure of 10 to 40 cm H The reaction conditions and the results are as shown in P p Table 2 below.

TABLE 2 Amount Beacof NH: Partial Pressure tion formed NH /N, of gas (0m. Hg) temp (00.) 20 (molar Catalyst (parts by weight) A; H2 C hours ratio) s 24 300 0.06 0.002 K graphite (2 2) s 24 350 o. 23 008 FeCh-graphite (0.2-2)... 10 30 300 0 0 K-FeCls-Graphite (2-0.2-2) 10 30 300 42 1 0 K-FeCls-graphite(2-12) 11- 30 300 24 0.52 Na-FeCls-graphite(20.22) 15 45 300 58 1.40 Rb-FeClagraphlte (1-0.2- 15 45 300 42 1.05 Li-FeCls-graphite (1-0.2-2). 15 45 300 2. 4 0. 04 Cs-FeCla-graphlte 15 45 300 52 0. 85

Example 3 TABLE 5 The ammonia synthesis was carried out by use of cata- Amourg lysts prepared with 2 grams of potassium, 2 parts of 0 ammonia graphite and 1 part of ruthenium or 0.6 part of osmium 3522; 23 m? as in Example 1. The surface area of each one of the Catalyst N2 b mic) catalysts was about m? per gram, respectively. The K -m0kel reaction conditions and the results are shown in Table chloride- 3 below 45 graphite 15 45 300 4.4 0. 073

TABLE 3 Amount Reacof NH: Partial Pressure tion formed NHa/Nz of gas (0m. Hg) temp (00.) 20 (molar Catalyst N1 Hz C hours ratio) 4 300 2 .2 .58 K-ruthenium 0hloridc-graphite-..-{ -9 200 1 03 15 22 a2 a K-osmium chloride-graphite 45 350 120 0 15 45 200 3.0 0.05

Example 4 EXAMPLE 6 The catalystic ammonia synthesis was carried out with air and H on the catalysts prepared as in Example 1. A small amount of water was obtained in addition to ammonia. N0 decrease in catalytic activity was observed even after conducting several runs. The reaction conditions and the results are shown in Table 4 below.

TABLE 4 Reac- Air Hydrotion NHa NHa/Nz Catalyst (parts (cm. gen temp. yield (molar by weight) Hg) (cm. Hg) C.) (00.) ratio) K-FeClsaphite 8.4 283 30 0.80 ($02-3 0 40 298 34 0. 86 K-OSClsraplute 19 40 307 28 0.84 20 40 303 35 0. 90 20 306 42 l. 10

Example 5 Into a 300 cc. U-shaped glass reactor was charged 2 parts of graphite (available from Union Carbide Com- 75 graphite TABLE 6 Amount of Reacammonia Partial Pressure tion formed NHa/N 2 of gas (0m. Hg) temp. (00.) 15 (molar Catalyst N2 Hz 0.) hours ratio) K-platinum chloride- Example 7 According to the procedures in Example 5, graphite and following transition metal halides were reacted at a temperature of 300 to 350 C. form a graphite-transition sium was added to the thus formed graphite-transition metal interlayer compound, and the mixture was subjected to a heat treatment at a temperature of 300 C. to form a three-component catalyst. The ammonia synthesis was carried out by use of 5 grams of these catalysts.

metal interlayer compound which was then reacted with 5 Th d th u h metallic potassium to form a three-component catalyst. T 8 i con Hons an e S are 5 Own 1 Ammonia synthesis was carried out by use of 4.5 grams a e e TABLE 9 Amount Par- Pres- Beac- Reae- 0t tial of sure tion tion ammonia NHs/Na gas (cm. temp. time, formed (molar Catalyst (parts by weight) N2 Hg) H2 0.) hours (00:) ratio) K-graphite-CrO; (2-2-1) 16.3 45.4 300 22 0.7 0.017 K-gmpmte 0+ 4 as a 3.3 as 14. 0 45. 0 310 24 4. 7 0. 034 K'grapmte'ms (H4) 15.1 45.4 320 24 4.7 0. 07s K-graphite-NiS (2-2-1) 14.5 45.8 300 24 0.7 0.012 K-graphite-FeS (2-2-0.2) 45 300 4. s 0. so

of these catalysts. The reaction conditions and the results 20 are shown in Table 7 below.

TABLE 7 We claim:

Amount 1. A process for preparing a catalyst comprising an 9 electron donor-acceptor complex, consisting essentially of Reaeammoma 25 a y t (Darts Partial Pressure tion formed NHs/N: graph1te, an alkali metal and a metal hallde, COmpI'lSll'lg by weight) of gas (cm. Hg) temp. (00.) 15 (molar K-graphite N1 Hz 0.) hours ratio) (a) heating a mixture of graph1te and a halide of a 10 300 0,06 Q0015 metal selected from the group consisting of iron, T g fggfi i 15 42 300 as (1014 30 ruthenium and osmium at a temperature of from H (2JZTIEI 3 15 40 300 L2 M20 about 250 to about 500 C. to form a graph1te- -Z2 2 0.5) 4 15 45 300 20 was metal-halide interlayer complex, ""Pdclz (b) adding an alkali metal to the resulting mterlayer (2- 1) 15 45 300 2.0 0.045 complex, and

'J a;%i,'"" 15 45 300 (c) heating the resulting mixture formed in (b) under 'g f fg 15 45 M15 a reduced pressure or in an inert gas atmosphere at C gi agu 15 45 300 (15 mm a tenliperiture abgve1 the metlng point of the alkali (Hi0 5) u 15 45 300 0.12 0.020 40 meta to orm sai eectron onor-acceptor complex, 2r 01r 15 300 0 m 0 020 wherem the weight who of the metal halide to graph1te 1s 1 7 .3 from 0.01/1 to 0.5/1, and the weight ratio of the alkali 15 45 300 metal to a graphite-metal halide interlayer complex is E 1 8 45 from 0.5/1 to 1.0/1.

xamp e 2. The process of claim 1, wherein the metal halide A graphite-transition metal interlayer compound was is f i chloride prepared at 300 to 350 C. by use of the transition metal chlorides shown in Table 8 as in Example 5, 2 grams of An electron donor afceptor comp 16X catalyst. re metallic potassium or metallic rubidium was added to 50 pared by the Process of Clam the thus formed graphite-transition metal interlayer com- An electron donor-acceptor complex catalyst prepound and the mixture was subjected to a heat treatment pared by th process of Claim 2, at a temperaturel of 3%)} C. for 20hourts1tof0 a f 5. An electron donor-acceptor complex catalyst precomponent cata yst. e ammoma syn es1s was carrle out by use of 46 grams of these catalysm The reaction pared by the process of Claim 1, wherein the alkali metal conditions and the results are shown in Table 8 below. Potasslum- References Cited TABLE 8 UNITED STATES PATENTS mom? 3 6 04 55 O Rem (mm ,17 8 3/ 19 Yeo etal 252447 Catalyst (parts Pgirggsl (gfsrigrg tag); 3,278,632 10/ 1966 Hamblmg et al. 252-447 byweight) Na fir 0 0.5 hours ratio) 3,658,721 4/1972 Tamaru et al. 423363 Nasgmphiw 3,660,028 5/ 1972 Tamaru et al. 252-447 gg, m 30 300 M W 1,053,951 2/1913 Bosch et al 423-352 Nga-grfihite- 3,287,086 11/1966 Cahn 423359 22555%? FOREIGN PATENTS (2 2-315)-.-- 10 30 300 1.0 0. 03 37, 64 3/1962 Canada 252-474 Example 9 7 DANIEL E. WYMAN, Primary Examiner A graphite-transition metal interlayer compound was P'E'KONOPKAASSIStam Examiner prepared with the use of the transition metal oxides and U S C1 X R transition metal sulfides given in Table 9 at a temperature of 300 to 350 C. as in Example 5. Two parts of potas- 252-447, 474; 423363 

